Detailed Project Report on Aluminium Slug

ALUMINIUM SLUG

[EIRI/EDPR/4335] J.C.: 2518XL

INTRODUCTION

An aluminium slugs for collapsible tube is obtained on a machine that cuts many slugs from a straight bar or coiled stock. The thickness, shape and size of the slug are set by a stop in the machine. A feeding mechanism feeds the aluminum bar or coil stock up against the stop and then a knife pushes against the aluminum material and shears of the slug. This is done at a fairly high speed of production. The cut slugs are then sent to a cold heading machine that reverse extrudes each aluminium slugs into a straight can shape. A plunger pushes against the slug inside a hole in a die and the material flows up the plunger to form a can. This is done in a full automatic production line where aluminium slugs are fed into the start unit of the line. They are then extruded, during which lips are rolled onto them. The inside of the shaped cans are lacquered, and next labels are rolled onto them. The finished empty cans are bunched together, strapped and stacked on pallets ready to ship. All the steps are done on one pro

duction line with no human touch from start to finish.

 Aluminum collapsible tubes are one of the most common packaging solutions in cosmetic, health care, pharmaceutical, food and adhesive industries. They are ideal for packing low viscosity products, such as lotion, cream, ointment and adhesive.

The tube collapses as the contents are squeezed out, effectively preventing suck back of air or contaminants and thus maximizes shelf life of product.

Aluminium collapsible tubes, covered under IS: 3107-1979 (First revision), are suitable for a wide range of liquids, semi-liquids, pastes & formulations containing soluble constituents.  All collapsible aluminium tubes with short screwed nozzle are well specified in this standard.  The aluminium collapsible tubes with other types of nozzles designs eg. Eye ointment tube, are covered under IS: 7852-1975.

Aluminium collapsible tubes are manufactured from Aluminium grade 19500 as per IS: 737 - 1974.  The wrought aluminium & alloys for   general engineering purposes belong   to this specification.  The collapsibility & permeability w.e.f. moisture and easy workability are the main characteristics of the aluminium slugs used for manufacturing collapsible tubes.

Aluminium of 99.70% purity is cast, rolled to predetermined thickness & blanked to provide cylindrical shapes of a defined diameter. These metal pieces are generally referred to in the industry as slugs. Slugs are heat treated to bring them to desired metallurgical state for fabricating into a collapsible tube. Mechanical fabrication an aluminium tube is accomplished in five stages of production, carried out automatically on a mass-production flow line.

The lubricated slugs are converted into tube shapes, by a process of impact extrusion in a specially designed press, with a shoulder & nozzle.  The tubes are transferred, next, to an automatic machining lathe for trimming to correct lengths & thread rolling on the nozzle portion.

The severe impact-extrusion forces, involved   in the transformation of slug to tube, cause a work-hardening in the tube. To provide flexibility or collapsibility, in the containers, they are annealed at temperature slightly below the melting point of the metal.

It is intended to prepare a Feasibility Report to install a Aluminium Slug production facility with a capacity of 1800 TPA as a Green Field Project.

COST ESTIMATION

Plant Capacity            6 MT/Day

Land & Building (3625 sq.mt.)    Rs. 3.32 Cr

Plant & Machinery                    Rs. 4.91 Cr

Working Capital for 1 Month    Rs. 2.28 Cr

Total Capital Investment          Rs. 11.07 Cr

Rate of Return                          46%

Break Even Point                      48%

CONTENTS

INTRODUCTION

USES & APPLICATIONS

ALUMINIUM SLUGS FOR COLLAPSIBLE TUBES

MARKET OVERVIEW

THE ALUMINUM SLUGS CAN BE SEGMENTED BY SHAPE, BY APPLICATION, AND BY END USE INDUSTRY.

ON THE BASIS OF SHAPE, THE GLOBAL ALUMINUM SLUGS ARE SEGMENTED INTO:

ON THE BASIS OF APPLICATION, THE GLOBAL ALUMINUM SLUGS ARE SEGMENTED INTO:

ON THE BASIS OF END USE INDUSTRY, THE GLOBAL ALUMINUM SLUGS ARE SEGMENTED INTO:

THE GLOBAL ALUMINUM SLUGS CAN BE SEGMENTED ON THE BASIS OF REGION SUCH AS:

PRESENT MANUFACTURER

PROPERTIES – RAW MATERIAL

THE CHEMICAL COMPOSITION OF WROUGHT ALUMINIUM AND ALUMINIUM ALLOY SHEET & STRIP CONFORM TO THE FOLLOWING TABLE:

MECHANICAL PROPERTIES

THE MECHANICAL PROPERTIES OF SHEET AND STRIP SHALL COMPLY WITH THE REQUIREMENT GIVEN IN TABLE:

ALUMINIUM CASTING

WROUGHT ALLOYS

FORMABILITY

RAW MATERIALS SUPPLIER

ALUMINIUM INGOT

ALUMINIUM SLUGS CHARACTERISTICS

THE APPLICATION AREA OF ALUMINUM SLUGS

SIZES OF SLUGS

SLUGS PACKAGING

MANUFACTURING PROCESS

CASTING

ALUMINIUM FLAT ROLLING

SHEARING

METAL SHEET PRESS

ANNEALING

TESTING & QUALITY CONTROL

CLEANING & PACKAGING

PROCESS FLOW

PROCESS STEPS

PLANT & MACHINERY (BROADLY)

PLANT AND MACHINERY SUPPLIERS/CONTRACTOR

FURNACE

ROLLING MILL MACHINERY

HYDRAULIC PRESS

DRILLING MACHINE

PLANT AND MACHINERY (GLOBAL)

UTILITIES REQUIREMENT (ESTIMATED - MONTH)

WASTE MANAGEMENT (ESTIMATED)

WATER

WASTE

PRINCIPLES OF PLANT LAYOUT

MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:

PLANT LOCATION FACTORS

PRIMARY FACTORS

RAW-MATERIAL SUPPLY:

MARKETS:

POWER AND FUEL SUPPLY:

WATER SUPPLY:

CLIMATE:

TRANSPORTATION:

WASTE DISPOSAL:

LABOR:

REGULATORY LAWS:

TAXES:

SITE CHARACTERISTICS:

COMMUNITY FACTORS:

FLOOD AND FIRE CONTROL:

ANTICIPATED ENVIRONMENTAL IMPACTS

CONSTRUCTION PHASE

OPERATION PHASE

MITIGATION MEASURES (PROPOSED)

HEALTH SAFETY & ENVIRONMENT

PROPOSED IMPLEMENTATION SCHEDULE

PROJECT FINANCIALS

BASIS & PRESUMPTIONS (FOR PROFITABILITY WORKINGS)

PRELIMINARY PLANT LAYOUT

APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING

03. PLANT AND MACHINERY

04. OTHER FIXED ASSESTS

05. FIXED CAPITAL

06. RAW MATERIAL

07. SALARY AND WAGES

08. UTILITIES AND OVERHEADS

09. TOTAL WORKING CAPITAL

10. TOTAL CAPITAL INVESTMENT

11. COST OF PRODUCTION

12. TURN OVER/ANNUM

13. BREAK EVEN POINT

14. RESOURCES FOR FINANCE

15. INSTALMENT PAYABLE IN 5 YEARS

16. DEPRECIATION CHART FOR 5 YEARS

17. PROFIT ANALYSIS FOR 5 YEARS

18. PROJECTED BALANCE SHEET FOR (5 YEARS)